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7 


THE  AMERICAN  SOCIETY  OF 
MECHANICAL  ENGINEERS 

29  WEST  THIRTY-NINTH  STREET,   NEW  YORK 


PROCESS   CHARTS 


FRANK  B.   GILBRETH 

Mem.Am.Soc.M.E. 

AND 

L.  M.  GILBRETH 


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<ir 


To  be  presented  at  the  Annual  Meeting  of  The  American  Society  of  Mechanical 
Engineers,  29  West  39  th  Street,  New  York,  December  5  to  9,  1921. 


The  Society  as  a  body  is  not  responsible  for  the  statements  of  facts  or  opinions  advanced  in  papers 

or  discussions     (C55) 


^ 


Qirr 

JOSEPH     MAYE« 
MAY-IS'  1938 


PROCESS   CHARTS 

FIRST   STEPS   IX   FINDING   THE   ONE   BEST   WAY  TO   DO   WORK 

By  Frank  B.  Gilbreth,  ]\Iontclair,  N.  J. 

Member  of  the  Society 

and 

L.  M.  Gilbreth,  Montclair,  N.  J. 

Non-Member 

The  process  chart  is  a  device  for  visualizing  a  process  as  a  means  of  improving 
it.  Every  detail  of  a  process  is  more  or  less  affected  by  every  other  detail;  therefore 
the  entire  process  must  be  presented  in  such  form  that  it  can  be  visualized  all  at  once 
before  any  changes  are  made  in  any  of  its  subdivisions.  In  any  subdivision  of  the 
process  under  examination,  any  changes  made  without  du£  consideration  of  all  the 
decisions  and  all  the  motions  that  precede  and  follow  that  subdivision  will  often  be 
found  unsuited  to  the  ultimate  plan  of  operation.  — ^ 

In  the  present  paper  the  author^  point  out  the  place  of  the  process  chart  in 
management  and  present  established  working  data  used  successfully  in  numerous 
working  installations  for  many  year^s,.^  They  also  ^point  out  its  simplicity,  field  of 
application,  its  relation  to  standardization,  etc.,  etc:    " '"'  . 

While  the  process-chart  methods  will  beftdpfutin  any  kind  of  work  and  under 
all  forms  of  management,  the  best  results  can  come,  the  authors  state,  only  where 
there  'is  a  mechanism  of  management  that  will  enforce  and  make  repetitive  the  con- 
ditions of  the  standards. 

T^HE  Process  Chart  is  a  device  for  visualizing  a  process  as  a  means 
of  improving  it.  Every  detail  of  a  process  is  more  or  less  affected 
by  every  other  detail;  therefore  the  entire  process  must  be  pre- 
sented in  such  form  that  it  can  be  visualized  all  at  once  before  any 
changes  are  made  in  any  of  its  subdivisions.  In  any  subdivision  of 
the  process  under  examination,  any  changes  made  without  due  con- 
sideration of  all  the  decisions  and  all  the  motions  that  precede  and 
follow  that  subdivision  will  often  be  found  unsuited  to  the  ultimate 
plan  of  operation. 


For  presentation  at  the  Annual  Meeting,  New  York,  December  5  to  9,  1921, 
of  The  American  Society  of  Mechanical  Engineers,  29  West  39th  Street, 
New  York.     All  papers  are  subject  to  revision. 

3 


r 


PROCESS    CHARTS 


PLACE    OF   PROCESS    CHART   IN   MANAGEMENT 

2  The  process  chart  is  a  record  of  present  conditions.  It 
presents,  in  simple,  easily  understood,  compact  form,  data  which 
must  be  collected  and  examined  before  any  improvement  in  existing 
conditions  and  methods  is  undertaken.  Even  if  existing  conditions 
are  apparently  satisfactory,  the  chart  is  useful  as  presenting  much 
information  in  condensed  form. 

3  The  process  chart  serves  as  an  indicator  of  profitable  changes. 
It  assists  in  preventing  "inventing  downward,"  and  stimulates  in- 
vention that  is  cumulative  and  of  permanent  value.  It  is  not  only 
the  first  step  in  visualizing  the  one  best  way  to  do  work,  but  is  useful 
in  every  stage  of  deriving  it. 

4  This  paper  presents  established  working  data  used  success- 
fully in  numerous  installations  for  many  years. 

FIELD    OF   APPLICATION 

5  The  process  chart  lends  itself  equally  well  to  the  routine  of 
*     production,  selling,  accounting  and  finance.    It  presents  both  simple 

and  complicated  problems  easily  and  successfully;  it  provides  records 
that  are  comparable;  it  assists  in  solving  problems  of  notification 
and  interdepartmental  discrepancies,  and  it  makes  possible  the  more 
efficient  utilization  of  similarities  in  different  kinds  of  work  and  in 
the  transfer  of  skill. 
U^  6  During  the  stress  of  unexpected  rush  in  production,  it  is 
often  considered  advisable  to  continue  existing  practice  in  present 
processes,  even  though  inefficient.  On  the  other  hand,  when  pro- 
duction is  normal  or  slow,  it  is  more  generally  conceded  that  processes 
^-.    can  profitably  be  bettered; 

7  The  use  of  this  process-chart  procedure  permits  recording 
the  existing  and  proposed  methods  and  changes  without  the  slightest 
fear  of  disturbing  or  disrupting  the  actual  work  itself,  and  also  regard- 

,      less  of  whether  business  conditions  are  usual  or  unusual. 

~'  8     Those  who  are  interested  in  improving  their  processes  of 

production  should  utilize  times  of  industrial  depression  for  that 
purpose.  Many  concerns  are  now  taking  such  action;  many  more 
could  undoubtedly  enter  upon  such  procedure  of  scrutinizing  all 
their  processes  with  the  idea  of  putting  them  in  the  best  possible 
condition,  if  they  knew  a  simple  proce4ure  of  such  analysis. 


F.    B.    AND    L.    M.    GILBRET^  5 

SIMPLICITY    OF   THE    PROCESS    CHART 

9  The  aim  of  the  process  chart  is  to  present  information  regard- 
ing existing  and  proposed  processes  iii  such  simple  form  that  such 
information  can  become  available  to  and  usable  by  the  greatest 
possible  number  of  people  in  an  organization  before  any  changes 
whatever  are  actually  made,  so  that  the  special  knowledge  and 
suggestions  of  those  in  positions  of  minor  importance  can  be  fully 
utilized. 

10  The  time  has  passed  —  if  it  ever  existed  —  when  the  engi- 
neer prided  himself  upon  the  abstruse  material  that  he  studied  and 

,  136.  All  the  time  of  ALL  our  workmen  mvist  be  entered  on 

the  regular  time  book  sheets.  When  men  are  employed  on  EXTRA 

WORK  see  additional  directions  below.  "^ 

137.  Time  book  sheets  must  be  mailed  to  the  office  the 
night  that  the  payroll  closes.  Send  at  the  same  time  all 
EXPENSE  ACCOUNTS,  CASH  ACCOUNTS,  (made  up  to  date)  and 
PAYMASTERS'  REQUISITION. 

138.  Send  original  time  sheet  to  the  office  regardless  of' 
its  appearance. 

139.  Keep  all  time  books  with  the  greatest  care. 

140.  DO  NOT  USE  A  NOTE  BOOK,   We  find  that  most  mistakes 
in  workmen's  time  are  caused  by  copying. 

141.  All  remarks  about  the  payroll  must  be  written  on  the 
time  sheet  itself. 

142.  The  full  time  of  every  one  of  our  men  must  appear 
on  the  regular  TIME  BOOK  ("TB")  sheets.   The  time  of  any  of 
workmen  which  is  to  be  charged  to  EXTRA  WORK  must  be  entered 
on  supplementary  sheets  under  the  proper  ORDER  LETTER  number. 

143.  Keep  separate  sheet  for  each  ORDER  LETTER  and  fill  , 
out  carefully  the  ORD.  LET.  (NUMBER)  AND  NATURE  OF  WORK. 

Fig.  1     Portion  of  Page  of  Written  System  Reproduced  Directly 
FROM  Typewritten  Sheets 

presented.  Today  engineering  ranks  with  the  other  sciences  in 
convejdng  ideas  in  a  form  that  is  immediately  usable.  We  avoid 
'* translating,"  interpreting  and  adapting,  thus  eliminating  waste. 

11  The  process  chart  has  met  the  tests  of  a  satisfactory  teach-  ' 
ing  device  from  the  psychological  standpoint,  as  well  as  of  a  satis- 
factory working  device  from  an  engineering  standpoint.  It  shows 
the  planned  process  as  well  as  the  present  process,  and  therefore 
gains  the  cooperation  of  those  affected.  In  many  instances  record- 
ing industrial  processes  in  process-chart  form  has  resulted  in  aston-, 
ishing  improvements.  "^ 

COLLECTING    THE   INFORMATION 

12  Process-chart  notes  and  information  should  be  collected  and 
set  down  in  sketch  form  by  a  highly  intelligent  man,  preferably  with 


6  .  *  PROCESS    CHARTS 

« 

an  engineering  training  and  experience,  but  who  need  not  necessarily 
have  been  previously  familiar  with  the  actual  details  of  the  processes. 
In  fact,  the  unbiased  eye  of  an  inteUigent  and  experienced  process- 
chart  maker  usually  brings  better  results  than  does  the  study  of  a  less 
keen  man  with  more  special  information  regarding  present  practices 
of  the  processes.  The  mere  act  of  investigating  sufficiently  to  make 
the  notes  in  goo'd  enough  condition  for  the  draftsman  to  copy  in- 
variably results  in  many  ideas  and  suggestions  for  improvement, 
and  all  of  these  suggestions,  good  and  bad,  should  be  retained  and 
filed  together  with  the  description  of  the  process  chart.  These  sug- 
gestions and  proposed  improvements  must  be  later  explained  to 
others,  such  as  boards  of  directors,  managers  and  foremen,  and  for 
best  results  also  to  certain  workmen  and  clerks  who  have  special 
craft  or  process  knowledge.  To  overcome  the  obstacles  due  to  habit, 
worship  of  tradition  and  prejudice,  the  more  intelligence  shown  by 
the  process-chart  recorder,  the  sooner  hearty  cooperation  of  all 
concerned  will  be  secured.  Any  one  can  make  this  form  of  process 
chart  with  no  previous  experience  in  making  such  charts,  but  the 
more  experience  one  has  in  making  them,  the  more  certain  standard 
combinations  of  operations,  inspection  and  transporting  can  be 
transferred  bodily  to  advantage  to  the  charts  of  proposed  processes. 


,  UTILIZING   SUGGESTIONS 

13  A  new  viewpoint  concerning  old  conditions  invariably 
comes  to  those  members  of  the  organization  who  have  become  so 
accustomed  t&  the  traditional  method  that  they  cannot-  easily 
visualize  a  new  method  without  prejudice  until  they  actually  see  it 
in  a  new  graphical  form.  After  the  rough  notes  of  the  process-chart 
maker  have  been  redrawn  and  blueprinted,  they  are  later  exhibited 

\^      in  the  executives'  theater. 

14  If  discussions  arise  as  to  the  correctness  of  the  presentation 
of  the  existing  facts,  or  as  to  further  details  of  the  operations  being 
studied,  as  shown  by  the  simple  symbols  of  the  process  chart,  the 
room  can  be  darkened  and  inexpensive  glass  diapositives  projected 
on  the  wall.  In  addition,  those '  present  may  be  supplied  with  a 
special  small  pocket  folding  stereoscope  for  use  with  the  same  glass 
diapositives. 

15  As  soon  as  the  old  or  existing  process  is  understood,  a  process 
chart  of  a  better  sequence  and  kind  of  operations  which  compose  it 
is  made.    The  procedure  for  this  is  the  same  for  all  cases  as  far  as 


r 


F.    B.    AND    L.    M.    GILBRETH  7 

they  are  carried  for  the  time  being,  but  of  course  those  processes 
which  warrant   the  most  study  should  be  carried  farthest  in  the 


BASKET  1 

}''"'!' 

J        J         . 

NUMBERS  1 

J      .J 

J        J        ,. 

CHANGE  ORDER 

SYMBOL 

DRAWING  NO. 

PATTERN  NO. 

ORDER  NO. 

STANDING  OROER  NO. 

MONTH 

DAY 

YEAR 

..i 

•• 

THE  FOLLOWING  CHANCES  TO  BE  MADE 


MAKING  CHANGE 


MANAGER 


]  I  ,     ADVER- 

COMP-     ,       SALES  TISINC 

TROLLER  I    DEPART-       DEPART- 


r. 


PURCHAS- 
ING 
DEPART. 


TRAFFIC 
DEPART. 

MENT  MENT       1        MENT 


EUPLOV- 
MENT 

DEPART- 
MENT 


ACCOUNT-! 
ORDER  INC 

DEPART.       DEPART-    ! 


COST 
DEPART- 
MENT 


TENDENT     TENDENT    ENGINEER 


CHART 
DEPART- 

MENT 


HOUR  I    DAY   I  ho™ 


-i L 


R      DAT   I  BOUR  I   DAT   |  BOW      DAT   I  HOUR  | 

J  I  J  I  J  I  J 


|HOURJDAT|HOURjDAT|HOUR|DAT|HOURjDAT| 


CHANGE  ORDER  No.         i) 


Fig.  2     Standard  Change  Order  Blank 

Note  that  all  blank  forms  should  be  thus  numbered  in  each  blank  space  to  be  filled  out  fo  r 
describing  clearly  the  One  Best  Way  to  Learn  Work. 


process-chart  procedure.  The  more  people  who  see  the  process 
chart  and  the  greater  detail  into  which  the  regular  process  charts 
are  divided,  the  more  suggestions  for  improvement  will  come  in. 


PROCESS    CHARTS 


RELATION   TO    STANDARDIZATION 


not  warrant  a  '^  write-up 

^'  STORES  PEOUISIT/ONED 

/\  STORES  BOUeHT. 

/\  STORES  RECEIVED 

^k  SEVERAL  KINDSOFCOHPONENTS-NOTDESIR/^BLE  TO  LIST  INDIVIDUALLY 

y^  WORKED  MATERIALS  RE0UISITIONED. 

Y\  WORKED  MATERIALS  ORDERED 

Y  Y  WORKED  MATERIALS  ON  HAND. 

(X  a)  MERCHANDISE  in STORABE  ready  TOSHIP 


STORAGE  AS  PART  OF  PROCESS 


V 


38 


PERMA  NENT  FILE  OF  ANY  DOCUMENTS  OR  MA  TERIALS . 

TEMPORARY  FILE  OFANY DOCUMENTS  OR  PAPERS 

OPERA  TION  SYMBOL  -  WITH  NUMBER.  SI6NIFIES  OPERA  TIOHN0.38.  OKBrVPERATUPTiaS. 


® 

® 

MOB 


o 


<2> 


Fig. 


16  There  is  no  process  that  warrants  a  process  chart  that  docs 
or  ^^ written  system. "7  Fig.  1  shows  a 
portion  of  a  page  of  the 
written  system  of  our 
organization  printed  in 
1899.  It  is  interesting 
to  note  that  it  was  re- 
produced directly  from 
typewritten  sheets  and 
without  being  set  up  in 
type,  and  it  is  believed 
to  be  the  first  instance 
on  record  of  a  book  be- 
ing printed  from  zinc 
etchings  made  from  type- 
written manuscript. 

17  Tke  more  care^ 
taken  in  making  the 
written  system,  the  more 
will  develop  the  need  for 
and  appreciation  of  the 
value  of  clearly  defined 
written  standards.  The 
better  and  the  more  de- 
tail in  which  the  written 
system  is  developed,  the 
better  and  easier  will  the 
standards  and  standing 
orders  be  developed. 

18  Standards  in 
writing  should  be  made, 
even  if  there  is  not  the 
managerial  mechanism 
necessary  to  enforce  and 
maintain  them.  Stand- 
ards made  even  with 
enforcing  mechanism 
absent  will  hasten  the 
day  when  the  enforcing 
and  maintaining    mech- 


MOVED  BY  OPERA  TOR  PERFORMING  OPERA  TION  N0.39 

NOVEDBYMAN. 

MOVED  BY  BOY 

MOVED  BY MES5EN6ER  BOY  ^ 

d)        MOVED  BY  ELEVATOR 
(J)        MOVED  BY  PNEUMA  TIC  TUBE 
©        MOVED  BY  CONVEYOR. 
©  QRA  VITY-  MOVED  BY  SRA  VITY  CONVEYOR. 
(QBELT     -  MOVED  BY  BEL  T  CONVEYOR. 

®  —  MOVED  BY  TRUCK. 

^     _,  „^o,^      (moved  BY  ELECTRIC  TRUCK(5UB5TITUTE-6A50UNE,HASD, 
(K)    EL  ECTRIC  -  {^^pj^  ^  ^^^  ^^y  g^  ) 


®  —  INFORMATION  OR  MESSAGE  MOVED  SV 
© —  MOVED  BY  MAIL  . 


TELEPHONE 


INSPECTION    FOR  QUALITY. 


<<n:»     INSPECTION  FOR  (QUALITY  BY  5EEIN6. 


INSPECTION  FOR  Q.UALITY  BY  5MELLIN6. 


INSPECTION  FOR  qUALITY  BY  HEARING. 


•^y    INSPECTION   FOR  QiUAUTY  BY  TASTING. 


INSPECTION  FOP  qUALiry  BY  FEELINQ. 


INSPECTION  FOR  QUALITY  BY  KINAESTHE5IA 


INSPECTION  FOR  QUANTITY. 
INSPECTION  FOR  QUANTITY  BY  i 


YYEIGNIN6. 
Y/EI5HT  COUNTING. 


INSPECTION  FOR  qUANTlTV  BY  COUNTING. 


INSPECTION  FOR  QUANTITY  BY  DRY  OR  LIQUID  MEASURING. 

(is  there  at  least  EN0U6H 
INSPECTION  FOR  (QUANTITY  BY  SEEING  \tS  A  PIECE  MISSING  FROM 
TRUCK  OR  PACKET? 


*     I  ^\     INSPECTION  FOR  (QUANTITY  BY  AUTOMATIC  COUNT/NS. 


INSPECT /ON  FOR  QUANTITY  AND  quALITV  (QUANTITY  MOST 

IMPORTANT). 


3   Stand AED  Symbols  for  Process  Charts 

(Continued  on  page  9) 


F.    B.    AND    L.    M.    GILBRETH 


9' 


r 


u 


anism  will  be  installed  and  continuously  operated.  The  jDrocedure 
of  making  the  standards  will  invariably  lead  to  the  simplifying  and 
improving;  of  the  various  steps  as  shown  on  the  process  chart. 

19  If  it  is  desirable  to  study,  improve  and  still  further  identify 
the  subject-matter  of  each  part  of  the  process  chart,  it  should  be 
submitted  to  the  regular  routine  process  of  standardization.  A 
standard  is  a  matter  of  degree.  In  its  best  form  it  is  identified  and 
defined  with  all  the  care  and  precision  of  the  best  practice  for  making 
the  standing  orders.  The  range,  however,  is  dependent  upon  the 
degree  of  perfection  with  which  provision  has  been  made  for  enforcing  . 
and  maintaining  standards. 

20  While  on  the  subject  of  range,  it  is  well  to  call  attention 
to  the  remarkable  attempts  of  Germany  and  Holland  to  provide 
national  standards.  These  standards  already  cover  a  very  wide 
field,  from  the  style  of  the  hand  lettering  and  the  rulings  to  be  used 
on  the  paper  on  which  the  standards  themselves  are  printed,  to  a 
metal  seat  for  a  harvester,  tractor  or  tank.  The  range,  in  fact, 
alread}'  covers  a  surpris-  ^ 
ingl}^  wide  list  of  things 
which  have  not  been 
properly  standardized  in 
America,  and  is  intended 
eventually  to  cover 
everything  that'  is  manu- 
factured in  quantity,  or 
that  will  for  an}'  other 
reason  reduce  costs  or 
improve  quality.  Al- 
though there  is  much  to 
criticise  in  these  foreign 
standards,  t  h  e  3^  are 
highly  meritorious, 
w^orthy  of  continuous  and 
careful  attention,  and  a 
great  credit  to  those  who 
have  deviseCFthem. 

21  It  must  be  re- 
membered that  the  kind 

of  standard  adopted  will  affect  the  process  almost  invariably.  There- 
fore standardization  must  be  considered  if  the  one  best  way  to  do  work 
is  to  be  derived. 


'NSPECr/ON  FOR  quALITY  AND  QUANTITY (QUAUTY  MOST  IMPORTANT) 

OVBfflNSPECTION  FOR  QUANTITY. 

OVERINSPFCTION  FOR  QUAUTY. 

INSPECT/ON  FOR  QUANTITY  ON  EXCEPTION  PRINCIPLE 

INSPECTION  FOR  QUALITY  ON  EXCEPTION  PRINCIPLE. 

OVERINSPECTION  FOfi  QUANTITY  ON  EXCEPTION  PRINCIPLE 

0VERIN5PECTION  FOR  QUALITY  ON  EXCEPTION  PRINCIPLE 

INSPECTION  FOR  QUANTITY  AND  OPERATION  PE)fFORffED  SIMULTANEOUSLY. 

INSPECTION  FOR  QUALITY  AND  OPERATION  PERFORMED  SIMULTANEOUSLY 

INSPECTION  FOR  QUANTITY  AND  QUAUTY  AND  OPERATION  PERFORMED 
SIMULTANEOUSLY  (QUANTITY  MOST  IMPORTANT). 

INSPECTION  FOR  QUALITY  AND  QUANTITY  AND  OPERATION  PERFORMED 

SIMULTANEOUSLY  (QUALITY  MOST  IMPORTANT). 
BLANK  FORM  USED  —  INDICATES  NOZ  COPY  OF  FORM  48S;IF  THERE 

IS  BUT  ONE  COPY  OF  FORM  MADE,  FORM  NUMBER  APPEARS  IN 

CENTER   OF  BLOCK  . 
REPORTS  NOT  HAYING  FORM  NUMBERS  WILL  HAVE  BRIEF  TITLE 

WRITTEN  IN  BLOCK 

A  SINGLE  DEPARTMENT  USED  MORE  THAN  ONCE. 

) BROKEN  LINES  INDICATE  PROCESS  OUTSIDE 

OF  THE  DEPARTMENT  CHARTED  -  USED  ON 
DEPARTMENTAL  CHARTS. 


Standard  S^-mbols  for  Process 
Charts   (Continued) 


10  PROCESS    CHARTS 

22  Particular  attention  should  be  called  to  the  fact  that  the 
creation  of  national  standards  of  manufacture,  even  to  the  smallest 
components  of  the  arts  and  trades,  means  also  the  stabilization  of 
employment  and  business  in  general,  because  manufacturers  without 
sufficient  orders  in  their  regular  lines  of  business  to  keep  going  will 
find  it  more  profitable,  in  many  instances,  to  manufacture  the 
national  standards  and  thus  to  turn  their  stores  inventories  into 
money  immediately,  rather  than  let  their  specially  trained  and  skilled 
men  leave  them,  with  all  the  disadvantages  of  a  high  labor  turnover. 
Here  is  an  endless  spiral  of  benefit,  for  the  more  chances  there  are 
for  a  manufacturer  to  dispose  of  his  inventory  for  cash  and  keep  his 
organization  together  a  little  longer,  even  in  times  of  general  timidity, 
the  more  he  will  dare  be  a  purchaser  of  raw  material,  for  the  process 
for  such  emergencies  can  be  standardized  and  ready.  The  result  is 
standardization  combined  with  stabilization  of  employment,  a  quick 
capital  turnover  and  a  low  labor  turnover. 

23  Many  fear  standardization  of  the  component  elements  of  a 
process  chart  as  something  from  which,  once  done,  it  will  be  difficult  to 
escape.  For  the  purpose  of  allaying  such  groundless  fears,  the  standard 
change  order,  Fig.  2,  has  been  provided.  This,  when  signed  by  the 
authorized  party,  instantly  changes,  or  for  a  certain  instance,  or  a 
certain  time,  waives  the  existing  standard  whether  it  relates  to  a 
thing,  a  method,  a  procedure  or  a  process.  It  will  be  noted  that  this 
change  order  blank  contains  provisions  for  the  notification  of,  and 
for  the  acknowledgment  of  receipt  of  notification  of,  all  persons  who 
are  concerned  with,  or  interested  in,  the  change. 

24  Note  that  in  the  lower  right-hand  corners  of  the  various 
spaces  in  Fig.  2  there  are  small  consecutive  numbers.  This  is  stand- 
ardized to  agree  with  write-ups  and  standing  orders  for  using 
standard  blank  forms.  It  not  only  makes  the  writing  of  the  standing 
order  more  simple,  exact  and  clear,  but  it  also  shortens  the  time  of 
the  learning  period  for  using  these  blank  forms.  This  is  a  valuable 
feature  at  all  times,  but  particularly  useful  during  the  transitory 
period  of  instalhng  new  methods  of  management. 

25  Experience  shows  that  if  process  charts  are  made  use  of, 
exceedingly  few  of  the  existing  blank  forms  survive  in^heir  present 
form.  The  savings  that  can  be  made  in  any  large  organization 
resulting  from  submitting  them  to  the  test  of  this  process  will  in 
variably  prove  it  to  be  a  good  investment. 

\  26     If  all  departments  of  the  United  States  Government  would 

adopt  two  features,  namely: 


F.    B.    AND    L.    M.    GILBRETH 


11 


a     Put  small  numbers  in  each  space  to  be  filled  out  on  all 

of  its  blank  forms,  and 
b     Make  write-ups  and  standing  orders  of  exactly  how  each 

blank  form  is  to  be  filled  out 

and  would  then  make  a  survey  and  criticism  in  accordance  with 
the  known  laws  of  micromotion  study,  the  resulting  savings  would 
be  astounding. 

27     We  believe  that,  as  a  result,  not  one  per  cent  of  present 


OaO 


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Fig.  4    Standaed  Process-Chart  Syivibols  Made  with  Standard  Celluloid 
Guides  and  Using  Standard  Pen  No.  707 

(One-fourth  actual  size) 

blank  forms  would  remain  unchanged.  All  Government  blank 
forms  that  we  have  seen  violate  all  laws  of  motion  study  and  learn- 
ing methods  of  least  waste.  ^ 

28  The  standing  order  is  for  enforcing  standards  and  other 
standing  orders.  This  has  already  been  described  in  a  paper  before 
this  Society. 


12 


PROCESS    CHARTS 


F.    B.    AND    L.    M.    GILBRETH 


13 


<<>n©®®©©® 


14 


PROCESS    CHARTS 


29  The  more  detail  in  which  the  standing  order  is  made,  the 
better.  The  more  the  procedure  is  described  by  it,  the  greater  will 
be  the  improvements  and  the  greater  the  automaticity  resulting.^ 

30  If  any  operation  of  the  process  shown  in  the  process  chart 
is  one  that  will  sufficiently  affect  similar  work,  then  motion  study 


MESSENGER ?„"o\Vo%"T'SrB;;;'KL';""         standing  order  no. 

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Fig.  6    Standing  Order  Blank 


should  be  made  of  each  part  of  the  process,  and  the  degree  to  which 
the  motion  study  should  be  carried  depends  upon  the  opportunities 
existing  therein  for  savings. 

^  See  Psychology  of  Management;  Applied  Motion  Study;  and  Bulletin  of 
the  Taylor  Society  for  June,  1921. 


F.    B.    AND    L.    M.    GILBRETH 


15 


31  If  the  operations  are 
highly  repetitive  or  consist  of 
parts  or  subdivisions  that  can 
be  transferred  to  the  study 
of  many  other  operations, 
then  micromotion  studies  al- 
ready made  can  be  referred 
to;  also  new  and  further 
micromotion  studies  may  be 
warranted  in  order  that  the 
details  of  method  with  the 
exact  times  of  each  of  the 
individual  subdivisions  of  the 
cycle  of  motions,  or  ''ther- 
bligs,"  as  they  are  called, 
that  compose  the  one  best 
way  known,  may  be  recorded 
for  constant  and  cumulative 
improvement.  Such  motion 
study  can  be  best  visualized 
if  seen  in  chart  form  and 
similar  process  charts  can  be 
made  of  any  or  all  of  the 
large  or  small  circles,  squares 
and  diamonds  shown  on  the 
process  charts.  These  sub- 
divided motion  charts  can  be 
made  of  each  and  all  of  the 
cycles  in  any  given  opera- 
tion. Much  benefit  can  often 
be  derived,  even  if  such 
motion  charts  are  made 
roughly.  For  best  results, 
and  especially  when  complete 
records  are  required,  such, 
for  example,  as  when  the 
process  charts  are  of  work 
that  is  highly  repetitive, 
micromotion  charts  can  be 
made  which  will  give  the 
maximum  amount  of  analysis 
and  visualization  of  com- 
ponent parts  of  the  existing 


CONSULTING  ENGINEERS  REEXAMINE  PROVEN 
FORMS  O.K.  FOR  PRINTING. 


STOREKEEPER  WRITES  PRINTING  REQUISITION. 
Q)HAS  NO  AUTHORITY  TO  SIGN  P.R. 


CONSULTING  ENGINEER  SIGNS  REQUISITION. 

C.E.  BECAUSE  OF  SLOW  MESSENGER  SERVICE. 

A55TSUPT  EXAMINES  FORMS  dc  REQUISITION 
QUESTIONS®  AS  TO  USE  OF  FORMS,  TUE NECESSITY 
AND  APPLICATION. 
O-H.'S  IFCONVINCED. 


ACCOUNTANT. 


A55T.  TO  PRESIDENT  PASSES  ON  IT  FROM 
AN  executive's  POINT  OF  V^W.  " 


PRINTING  DEPT  DECIDES  WHETHER  OR  NOT 
TO  PRINT  IN  PLANT 

DICTATES  PRINTING  SPECIFICATIONS  AND 
PURCHASE  REQUISITION. 
STENOGRAPHER  TYPES  PURCHASE  REQUISI- 
TION AND  SPECIFICATION  SHEET. 


BUYER  TAKES  IT  UP  YYITH  PURCHASING  AGENT 


PURCHASING  AGENT  INSPECTS  FOR  QUANTITY 
AND  QUAUTYAND  INSTRUCTS®  WHAT  TO  DO. 


BUYER  SENDS        (a)  BY  SENDING  SAMPLE  OR 
FOR  QUOTATIONS    (b)  BY  HAVING  PRINTERS  COME. 


'  a  \         BUYER  DECIDES  ON  BASIS  OF  PR  ICE  AND 
-^  ^        DELIVERY  WHO  GETS  THE  JOB. 


JTMOB 


STENOGRAPHER  TYPES  PURCHASE  ORDER. 


STENOGRAPHER  SEALS  AND  STAMPS  LETTER. 


MESSENGER  DELIVERS  TO  POST  OFFICE  AND 
PRINTER  DOES  NOT  VET  MAVE ORDER 

Fig.    7     Process    Chart    for    Ordering 
Blank  Forms  —  Present  Method 


16  PROCESS    CHARTS 

and  proposed  processes.  These  can  be  still  further  visualized  by  the 
chronocyclegraph  processes.  Both  the  chronocyclegrap^  and  the 
micromotion  process  have  been  described  before  the  Society  and 
more  recent  developments  in  these  methods  and  devices  for  visualiz- 
ing existing  and  proposed  processes  will  be  the  subject  of  a  later  paper. 
32  The  records  of  the  micromotion  study  and  the  chronocycle- 
graph methods  and  devices  present  permanently  all  the  facts  in  such 
form  that  they  can  be  used  at  any  time.  These  photographic  records 
can  be  studied  as  slowly  as  desired,  regardless  of  how  fast  the  motions 
of  the  process  were  actually  made  and  the  marvels  of  the  details  of 

C.£.  WRITES  RE9UI5ITIOH. 


e    ]  Buy ER  HANDS  TO  STENOGR/^PHER. 


5TEN06RAPHER  TYPES  PURCHASE  ORDER. 


9    )  PURCHASING  AGENT  SIGNS   P.O. 


STENOGRAPHER  STAMPS  ANDSEAL5  PO. 


I&AIL  ROOM  PLACES  IN  MAIL  BAS. 

Fig.  8     Proposed  Process  Chart  for  First  Orders 

superskill,  unknown  and  unrecognized  even  by  those  who  possess  it, 
can  be  studied  at  will,  leisurely  and  intensively,  by  learners  every- 
where, far  as  well  as  near.  If  desired,  these  errorless  records  may 
be  used  only  as  far  as  to  fill  the  need  of  present  requirements,  or  they 
may  be  laid  away  until  further  needs  demand  further  study,  such 
records  being  in  such  perfect  detail  that  they  are  practically  as  usable 
When  old  as  when  new.  These  permanent  records  of  complete  se- 
quences of  details  of  complete  processes  furnish  the  foundation  of 
the  best  kind  of  trade  and  industrial  education,  namely,  the  dis- 
semination^ of  detailed  instructions  as  to  the  synthesized  processes 
of  the  best  workers  obtainable. 

33  These  synthesized  records  of  details  of  processes  in  turn  may 
be  further  combined  and  large  units  of  standard  practice  become 
available  for  the  synthesis  of  complete  operations  in  process  charts. 


F.    B.    AND    L.    M.    GILBRETH  17 

» 

34  AVhile  the  process-chart  methods  will  be  helpful  in  any 
kind  of  work  and  under  all  forms  of  management,  the  best  results 
can  come  only  where  there  is  a  mechanism  of  management  that  will 
enforce  and  make  repetitive  the  conditions  of  the  standards. 

MECHANISM    OF   MAKING    PROCESS    CHARTS 

35  There  are  shown  herewith: 

a  The  symbols  used  with  their  meanings  (Fig.  3) 

h  The  mechanical  devices  for  making  the  symbols  on  the 

process  charts  (Fig.  4) 
c  Completed  process  chart  (Fig.  5) 
d  Accompanying  forms  (Fig.  6) 
e  Illustrations  of  collecting  and  using  data. 

SUMMARY 

36  The  procedure  for  making,  examining  and  improving  a 
process  is,  therefore,  preferably  as  follows: 

a  Examine  process  and  record  with  rough  notes  and  stereoscopic 
diapositives  the  existing  process  in  detail 

h  Have  draftsman  copy  rough  notes  in  form  for  blueprinting, 
photographic  projection  and  exhibition  to  executives  and  others 

c  Show  the  diapositives  with  stereoscope  and  lantern  slides  of 
procesi  charts  in  executives'  theater  to  executives  and  workers 

d  Improve  present  methods  by  the  use  of  — 

1  Suggestion  system 

2  Written    description    of    new    methods    or    '^write-ups," 

'^manuals,"    ''codes,"    ''written   systems,"    as   they   are 
variously  called 

3  Standards 

4  Standing  orders 

5  Motion  study 

6  Micromotion  studies  and  chronocyclegraphs  for  obtaining 

and  recording  the  One  Best  Way  to  do  Work. 
e  Make  process  chart  of  the  process  as  finally  adopted  as  a  base 
for  still  further  and  cumulative  improvement. 

37  Note  that  — 

a  Visualizing  processes  does  not  necessarily  mean  changing  the 

processes 
h  Process  charts  pay. 


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